Repairs Honda 20hp MOD: GXV620K1, ENGINE: QYF

[msmallenginerepair]

I have a client with a Honda 20hp MOD: GXV620K1, ENGINE: QYF. It has an intermittent starting issue. When the ignition key is switched on, sometimes it will fire right up. Other times it clicks in the starter. The clicking is caused by the starter gear plunging up against the flywheel but not rotating. I started by testing the system at the battery = good. Next I moved on to the safety interlock system of the mower (Hustler Fastrak) just to rule that out and that passed. Next I tested the voltage coming from the positive battery to the solenoid = 12.84v. I then tested the voltage coming thru the ignition switch to the solenoid spade = 12.84v. So I replaced the piggy-back solenoid with a new one. Same problem. So then I checked the valve lash and found that to be fine, within specs. Finally, I moved on to the starter and replaced it with a new aftermarket starter from Oregon Parts. The starter will receive electricity and plunge the gear but won't rotate. Once again I tested all voltage going to the starter, and I am getting over 12 v. Do you think the new starter is bad, or am I missing something? What is the proper way to bench test these starters? For starters, I have always just applied voltage and ground and either they plunge and spin or they don't. But I don't have much experience with this machine. What else could this issue be? Thank you to all in advance for your time and experience!

 

[Honda Tech]

I have seen this issue a few times. If you are also a Honda Engine dealer, contact your distributor and see if they happen to have a parts engine lying around that you can get the flywheel and starter from. The Honda k1 series Horizontal and Vertical shaft engines use the same flywheel.
This issue arises from the fact that the flywheel actually comes to a stop in the same position, over and over, which eventually causes the starter ring to wear. Replacing the flywheel and electric starter will resolve your issue.

 

[msmallenginerepair]

I have seen this issue a few times. If you are also a Honda Engine dealer, contact your distributor and see if they happen to have a parts engine lying around that you can get the flywheel and starter from. The Honda k1 series Horizontal and Vertical shaft engines use the same flywheel.
This issue arises from the fact that the flywheel actually comes to a stop in the same position, over and over, which eventually causes the starter ring to wear. Replacing the flywheel and electric starter will resolve your issue.

Thanks for your reply! I would never have guessed. So I called around to every Honda distributor in my area and none of them have ever heard of this issue, and not a single one has a used K1 series flywheel. I guess I will try to get one from ebay and then see if the issue is fixed.

 

[Honda Tech]

Thanks for your reply! I would never have guessed. So I called around to every Honda distributor in my area and none of them have ever heard of this issue, and not a single one has a used K1 series flywheel. I guess I will try to get one from ebay and then see if the issue is fixed.

No real surprise there. This engine has been out of production for awhile and any service managers that would have been aware of the issue have probably moved on. I myself have only seen this issue 3 or 4 times.

 

[msmallenginerepair]

Honda Tech, would you be so kind as to describe the process for bench testing one of these GXV K1 series starters? I'm wondering if I am doing something wrong. Thanks again!

 

[Honda Tech]

See attached. Here is all that is offered. The bench test procedure would be the same a B&S.

 

[msmallenginerepair]

See attached. Here is all that is offered. The bench test procedure would be the same a B&S.

Thanks again! I'm looking forward to trying out your suggestions.